Method for applying an underlayment layer to trucking cargo

ABSTRACT

A method for applying an underlayment layer to trucking cargo includes providing a roll of underlayment layer that is independent of the trucking cargo and a vehicle that transports the trucking cargo. The leading edge of the underlayment layer is secured and the underlayment layer is dispensed from the roll of underlayment layer such that the underlayment layer is applied to the trucking cargo in the longitudinal direction of the trucking cargo so as to cover the trucking cargo.

CROSS REFERENCE TO RELATED APPLICATION

This application dams priority to and is a divisional of U.S. patentapplication Ser. No. 12/123,671 filed May 20, 2008, the contents ofwhich are herein incorporated by reference.

FIELD OF THE INVENTION

The present invention generally relates to an apparatus and method forcovering large containers and more particularly to the process ofcovering loaded trucks and rail cars with tarps or related coverings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of an apparatus for applying an underlayment layerto trucking cargo, in accordance with an exemplary embodiment.

FIG. 2 is a perspective view of the roll of the underlayment layer ofthe exemplary embodiment of FIG. 1.

FIG. 3 is the side view of a vertical driving mechanism of the apparatusof FIG. 2.

FIG. 4 is a top view of a portion of the apparatus of the exemplaryembodiment of FIG. 1, illustrating a horizontal driving mechanism.

FIG. 5 is a perspective view of the roll of underlayment layer with adriving motor and a cutting mechanism added to the exemplary embodimentof FIG. 1.

FIG. 6, FIG. 8 and FIG. 9 are side views of the apparatus of FIG. 1illustrating various steps involved in the method of applying anunderlayment layer to the trucking cargo.

FIG. 7 is a top view of the apparatus of FIG. 1 illustrating a stepinvolved in the method of applying an underlayment layer to the truckingcargo.

FIG. 10 is a side view of an apparatus for applying an underlaymentlayer to a trucking cargo, in accordance with another exemplaryembodiment.

FIG. 11 is a side view of an apparatus for applying an underlaymentlayer to a trucking cargo, in accordance with yet another exemplaryembodiment.

FIG. 12 is a side view of the apparatus for applying an underlaymentlayer that also includes tarp application, in accordance with anotherexemplary embodiment.

DETAILED DESCRIPTION

Each embodiment of the present invention provides for an apparatus 10and method for applying an underlayment layer 12 to a trucking cargo 22.This can be done without requiring a person climb on the trailer 20carrying the trucking cargo 22 or on top of the trucking cargo 22 toapply the underlayment layer 12 thereto. Such an arrangement may thusincrease user safety related to the application of an underlayment layer12 to trucking cargo 22. The underlayment layer 12 acts as an additionalbarrier and hence protects the trucking cargo 22 from natural elements.A tarp or other protective member may alternatively be added on top ofthe underlayment layer 12 to further protect the trucking cargo 22during transport. The underlayment layer 12 may be made of a suitablematerial, for example plastic or the like, for providing the necessaryprotection to the trucking cargo 22. The term trucking cargo 22 usedthroughout the description refers to any load which is being transportedby a heavy vehicle.

Reference will now be made in detail to the embodiments of theinvention, examples of which are illustrated in the drawings.

Prior to being applied to the trucking cargo 22, the underlayment layer12 can be formed into a continuous roll 14 by being folded towards itscenter, once or a number of times. The underlayment layer 12, withoutlimitation, is 20 feet wide. It may be folded 4 times towards its centerto make it 5 feet wide. However, it is to be understood that theunderlayment layer 12 can be of a different size and folded any numberof times as contemplated within the scope of the invention. Theapparatus 10 includes roll 14 of the underlayment layer 12 thus formedand a rod 24. The rod 24 is disposed through the roll 14 of underlaymentlayer 12. According to one exemplary embodiment, as seen in FIG. 1, theroll 14 of the underlayment layer 12 may be supported by a frame 16.

In accordance with certain exemplary embodiments, the roll 14 may befive feet wide and the rod 24 may be sixteen feet wide. Any number ofrolls may be placed on the rod 24. For example, two rolls 14 ofdissimilar width can be placed onto the rod 24 so that the apparatus 10can dispense underlayment layers 12 of different widths. The rolls 14can be moved from side to side on the rod 24 as desired for properalignment. In another arrangement, three rolls 14 can be used. The rolls14 can be perforated or unperforated so that added functionality may berealized. Additional arrangements are possible in which one or more rods24 can be used. Here, for example, three rods 24 can be present so thatone rod 24 hangs from another.

Frame 16 may be a free standing structure positioned on the ground 38.The free standing structure 16, without limitation, may comprise of aplurality of vertical support members 90 attached to a top rectangularframe 92. The free standing structure 16 may optionally be provided withwheels or other rotating elements, below the vertical support members 90to make it portable.

FIG. 2 illustrates a perspective view of the roll 14 of the underlaymentlayer 12 loaded on rod 24. The roll 14 may be suspended from the toprectangular frame 92 by a pair of straps 64 and 66, or a pair of cablesor the like. A pair of drums 60 and 62 may be located on opposite endsof the rod 24. The drums 60 and 62 can be supported by the pair ofstraps 64 and 66. The straps 64 and 66 may be flexible in nature. Theroll 14 can be configured to be moved vertically with respect to theground 38 such that the roll 14 of the underlayment layer 12 can movecloser to and farther from the ground 38. The vertical bidirectionalmovement of the roll 14 in the vertical direction 32 is achieved by theuse of a vertical driving mechanism 28.

Referring to FIG. 3, which illustrates a side view of the verticaldriving mechanism 28, the strap 64 extends around a first directionalroller 68, drum 60 and a second directional roller 70. A take-up roller72 can be used to wrap the strap 64 around thereon. The take-up roller72 can be rotated clockwise or counter-clockwise by the use of avertical driving motor 44 (illustrated in FIG. 4). As the take-up roller72 is rotated, strap 64 winds around take-up roller 72 and hence thedrum 60 is elevated. Rotating the take-up roller 72 in the oppositedirection causes the strap 64 to unwind therefrom and thus lowering ofthe drum 60. In a similar manner, drum 62 can be raised and lowered asthe take-up roller 72 rotates.

Referring to FIG. 4, the strap 66, which extends around the directionalrollers 74 and 76, winds around the take-up roller 72 as it is rotatedby the vertical driving motor 44. Thus, as the take-up roller 72 isrotated by the vertical driving motor 44, the drums 60 and 62 are raisedor lowered. This causes the roll 14 to be moved vertically with respectto the free standing structure 16 so that the roll 14 moves closer toand farther from the ground 38.

Although described as being capable of being moved in the verticaldirection 32, it is to be understood that other exemplary embodimentsare possible in which the roll 14 does not move in the verticaldirection 32. For example, the roll 14 may be located a particularheight from the ground, and the leading edge 48 can be grasped so as todispense the underlayment layer 12 from roll 14.

When the frame 16 is a free standing structure, the roll 14 can beconfigured to move horizontally with respect to the free standingstructure 16. As illustrated in FIG. 4, a horizontal driving mechanism30 may be employed to achieve the horizontal movement of roll 14. Racks78 may be present on the top rectangular frame 92 of the free standingstructure 16. The racks 78 may be fixedly or removably attached upon thetop rectangular frame 92 by means of bolts or other fastening elements.The racks 78 extend along the length of the top rectangular frame 92.The horizontal driving mechanism 30 has a pair of pinions 80 whichcomplement the racks 78 and are capable of meshing therewith. Thepinions 80 can be driven by horizontal driving motors 46. The pinions 80may be fixedly or removably attached to a pair of platforms 86 and 88 bymeans of bolts or other fastening elements. The platforms 86 and 88support the take-up roller 72 thereon. As the pinions 80 are driven bythe horizontal driving motors 46, the pinions 80 move along the lengthsof the racks 78. The movement of the pinions 80 causes the platforms 86and 88 to move horizontally along the racks 78 in the horizontaldirection 34. Hence, the take-up roller 72 and the roll 14, along withthe directional rollers 68, 70, 74 and 76 may move horizontally alongracks 78.

FIG. 5 illustrates an exemplary embodiment in which rod 24 is driven bymeans of a motor 26. This rotation results in the winding and unwindingof the underlayment layer 12 depending upon the direction of rotation ofthe rod 24. Thus, simultaneous operation of the motor 26 and thehorizontal driving motor 46 are possible to result in dispensing of theunderlayment layer 12 roll 14 while roll 14 moves horizontally along theracks 78. After a desired length of the underlayment layer 12 isdispensed from the roll 14, the underlayment layer 12 may be cut at adesired position by means of a cutting mechanism 42. The cuttingmechanism 42 may be an automatic cutting mechanism in accordance withone exemplary embodiment. The cutting mechanism 42 may employ anysuitable means capable of cutting the underlayment layer 12. In otherarrangements, a cutting mechanism 42 need not be present. For example, autility knife or the like could be used in order to cut the underlaymentlayer 12. However, it is to be understood that in alternate embodimentsthe underlayment layer 12 may have perforations 56 defined atpredetermined lengths to facilitate easy tearing or cutting of theunderlayment layer 12 without the need of a cutting mechanism 42.

Referring back to FIG. 1, a trailer 20 loaded with a trucking cargo 22is driven by a cab 18 and positioned beneath the free standing structure16. The rod 24 carrying the roll 14 of underlayment layer 12 issupported by the free standing structure 16. The trailer 20 is stationedon the ground 38 such that the roll 14 is positioned proximate to thefront 52 of the trailer 20. As the vertical driving mechanism 28 (FIG. 2and FIG. 3) is energized, the roll 14 is lowered to allow an operator toreach the roll 14. As illustrated in FIG. 6 and FIG. 7, the roll 14 islowered to a level which allows the operator to be able to pull aleading edge 48 of the underlayment layer 12 and secure it to thetrailer 20. The leading edge 48 can be secured at a position proximateto a front 52 of the trailer 20. The operator may be personnel or anyautomated mechanism configured to secure the leading edge 48 proximateto the front 52 of the trailer 20.

The leading edge 48 may be secured to the trailer 20 by various means.For example, the underlayment layer 12 can be tied at the sides of thetrailer 20. Additionally or alternatively, adhesives may be used toeffect such an attachment. The underlayment layer 12 can be wide enoughto accommodate the entire width 96 of the trucking cargo 22. As soon asthe operator pulls the leading edge 48 of the underlayment layer 12, therod 24 is rotated by the motor 26 (seen in FIG. 5), causing theunderlayment layer 12 to be dispensed from the roll 14.

After the leading edge 48 of the underlayment layer 12 is secured to thetrailer 20, the horizontal driving mechanism 30 is activated. Activationof the horizontal driving mechanism results in the movement of roll 14in a horizontal plane parallel to the ground 38 along the length of thefree standing structure 16 (as illustrated in FIG. 4). The roll 14 movesalong racks 78 from a position proximate to the front 52 towards theback 54 of trailer 20. Also, the roll 14 is raised to a sufficientheight to ensure that the horizontal movement of the roll 14 is nothindered by the trucking cargo 22.

While the roll 14 moves in a horizontal plane, the underlayment layer 12is unfolded from the roll 14 so that the trucking cargo 22 positionedunderneath may be draped with the underlayment layer 12. Referring toFIG. 8, the dispensed length of the underlayment layer 12 is sufficientto drape the entire length 40 of the trucking cargo 22. However, it isto be understood that other arrangements are possible in which theunderlayment layer 12 is not positioned over the entire length 40 oftrucking cargo 22. Thereafter, the underlayment layer 12 is cut at adesired position, by the use of the cutting mechanism 42 illustrated inFIG. 5.

As illustrated in FIG. 9, after the underlayment layer 12 is detachedfrom the roll 14, the trailing edge 50 of the underlayment layer 12 issecured to the back 54 of the trailer 20. The trailing edge 50 of theunderlayment layer 12 may either be tied at the back 54 of the trailer20 or secured using tape or other conventional adhesives capable ofholding the underlayment layer 12 in place. The trucking cargo 22 may befully covered by the underlayment layer 12.

The motors 26, 44 and 46 may be gear motors of 1½ HP. Motors of varioustypes and powers may be used in other embodiments depending upon theweight and requirement of the underlayment layer 12. The verticaldriving mechanism 28 and the horizontal driving mechanism 30 may beoperated by an electric drive system, a hydraulic drive system, apneumatic drive system or any other type of drive system.

A second embodiment of the apparatus is explained hereinafter. Thesecond embodiment is similar to the first embodiment describedhereinabove except that the present embodiment facilitates applying theunderlayment layer 12 to the trucking cargo 22 when the horizontal drivemechanism 30 is not present or is inoperative. The present embodimentutilizes the horizontal movement of the trailer 20 with respect to thefree standing structure 16 to completely cover the trucking cargo 22.This eliminates the need for the horizontal movement of the rod 24 andthe horizontal driving mechanism 30 used in the first embodiment. As inthe first embodiment, the vertical driving mechanism 28 ensures thesmooth lifting or lowering of the roll 14 closer to and farther from theground 38. The trailer 20 may be parked directly below the free standingstructure 16. In this regard, the roll 14 is positioned proximate to thefront 52 of the trailer 20. The roll 14 may be lowered to allow theoperator to pull the leading edge 48 of the underlayment layer 12. Theproximity of the roll 14 to the front 52 of the trailer 20 enables theoperator to conveniently secure the leading edge 48 of the underlaymentlayer 12 thereto. Thereafter, the roll 14 can be raised above the heightof the trucking cargo 22.

As illustrated in FIG. 10, the trailer 20 is then driven forward in thehorizontal direction 34. The roll 14 is raised to a sufficient heightwhich allows the trucking cargo 22 to be driven beneath the freestanding structure 16, without hitting the roll 14. As the trailer 20moves forward in the horizontal direction 34, the leading edge 48 of theunderlayment layer 12 is pulled and the underlayment layer 12 is furtherdispensed from the roll 14 over the trucking cargo 22. The truckingcargo 22 driven beneath the free standing structure 16 is draped by thedispensed underlayment layer 12. The underlayment layer 12 is wideenough to accommodate the width 96 of the trucking cargo 22. The speedof the trailer 20, and hence of the trucking cargo 22, should becontrolled to ensure uniform and smooth draping of the trucking cargo22. It may be contemplated that in certain situations alternativemethods of covering the trucking cargo 22 could be used. For example, inaccordance with one alternative embodiment, the horizontal movement ofthe trucking cargo 22 may be utilized in conjunction with the horizontalmovement of the roll 14 used in the first embodiment.

A third embodiment of the apparatus 10 is illustrated in FIG. 11. Inthis exemplary embodiment, the roll 14 of underlayment layer 12 issupported by the frame 16. Frame 16 may be attached to a ceiling 36. Thetrucking cargo 22 to be covered is parked directly beneath frame 16. Therod 24 carrying the roll 14 is then rotated to unwind the underlaymentlayer 12 from the roll 14. A sufficient length of the underlayment layer12 is unfolded and dispensed from the roll 14, such that the operator isable to reach the leading edge 48 of the underlayment layer 12. As theroll 14 mounted on the frame 16 is situated more proximate to the front52 of the trailer 20, the operator conveniently secures the leading edge48 of underlayment layer 12 thereto.

As in the second embodiment, the trucking cargo 22 is drivenhorizontally relative to the frame 16 in the horizontal direction 34depicted in FIG. 11. As the trailer 20 moves forward in the horizontaldirection 34, the leading edge 48 of the underlayment layer 12 is pulledand the underlayment layer 12 is further dispensed from the roll 14 overthe trucking cargo 22. The trucking cargo 22 being driven beneath theframe 16 is draped by the dispensed underlayment layer 12 which is wideenough to accommodate the width 96 of the trucking cargo 22. The speedof the trailer 20 and hence of the trucking cargo 22 should becontrolled to ensure uniform and smooth draping of the trucking cargo22.

The roll 14 may be motorized so that it can rotate in order to dispensethe underlayment layer 12. Alternatively, the roll 14 need not arrangedso that it is automatically driven. Instead, the roll 14 can rotatefreely on rod 24 or another mechanism due to forces being applied to theunderlayment layer 12. In this regard, the underlayment layer 12 can bepulled from the roll 14 without automatically rotating the roll 14.Other embodiments are possible in which the underlayment layer 12 isdispensed from the roll 14 through both a combination of pulling ofunderlayment layer 12 and a rotation of the roll 14.

FIG. 12 illustrates an alternative exemplary embodiment of the apparatus10. Here, a roll 14 is positioned at the front portion of the frame 16and extends in the longitudinal direction from the vertical supportmember 90 so that the vehicle first encounters the roll 14 before thetrucking cargo 22 is positioned between the vertical support members 90.The underlayment layer 12 can be attached to the trailer 20 and/ortrucking cargo 22 and the trailer 20 can be moved from left to right inFIG. 12 so that the underlayment layer 12 is rolled from the rod 24 andapplied to the trucking cargo 22 in the longitudinal direction from thefront to the back of the trucking cargo 22.

The roll 14 may be arranged so that it can move vertically with respectto the ground but not horizontally with respect to the ground. Thisarrangement allows the leading edge 48 of the underlayment layer 12 tobe placed into proper position for attachment. The roll 14 may spinfreely on the rod 24 so that the underlayment layer 12 can be pulledtherefrom without having to be motor driven.

The arrangement in FIG. 12 also includes a tarp application member 100that is supported by the frame 16. The tarp application member 100 canbe used to apply a tarp 102 to the trucking cargo 22 after theunderlayment layer 12 is applied to the trucking cargo 22. In thisregard, the tarp application member 100 has a tarp support frame 104that may engage the vertical support members 90 and be moveabletherewith. An independent motor may be used to move the tarp supportframe 104 vertically, or a motor used in connection with the roll 14 maybe employed. The tarp application member 100 includes a number of straps106 that are stretched between the tarp support frame 104 in order tosupport the tarp 102 which is generally unfolded. The trucking cargo 22can be located under the tarp 102, and the tarp support frame 104 can belowered so that the tarp 102 is placed on top of the trucking cargo 22.The straps 106 may be removed and the tarp 102 can be secured to thetrucking cargo 22. Alternatively, the straps 106 may be used to effectattachment of the tarp 102 to the trucking cargo 22. The vehicle andtrucking cargo 22 may thus move through the frame 16 until theunderlayment layer 12 is properly applied, and the vehicle and truckingcargo 22 may be reversed back into the frame 16 so that the tarp 102 canbe applied.

The underlayment layer 12 may be made our of a variety of materials inaccordance with certain exemplary embodiments. For example, theunderlayment layer 12 may be made out of plastic in accordance withcertain embodiments. The underlayment layer 12 can be placed on thetrucking cargo 22 in order to provide protection during transport. Theunderlayment layer 12 may be paced on the trucking cargo 22 in order tofunction as a moisture resistance layer. The underlayment layer 12 maymade of a flexible material and may be waterproof in accordance withcertain exemplary embodiments. A tarp, such as a canvas tarp, can beplaced on top of the underlayment layer 12 to further protect thetrucking cargo 22. In accordance with other exemplary embodiments, atarp is not placed on top of the underlayment layer.

The underlayment layer 12 may be applied to the trucking cargo 22 in thelongitudinal direction so as to cover the trucking cargo 22. As usedherein, including in the claims, the term “longitudinal direction”refers to the direction from the front of the vehicle to the back of thevehicle or from the back of the vehicle to the front of the vehicle. Thelongitudinal direction may thus be from the front of the trailer 52 tothe back of the trailer 54. The longitudinal direction of the truckingcargo 22 is likewise the same in that it may also extend from the frontof the trailer 52 to the back of the trailer 54, or from the back of thetrailer 54 to the front of the trailer 52. The term, “transversedirection” refers to the direction from the side of the vehicle/truckingcargo 22 to the opposite side of the vehicle/trucking cargo 22. Forexample, the transverse direction may be from the left side of thetrucking cargo 22 or trailer 20 to the right side of the trucking cargo22 or trailer 20.

Various modifications to the above mentioned embodiments are possible.For example, with respect to the first embodiment, it may beinconvenient to start applying the underlayment layer 12 by securing theleading edge 48 proximate to the front 52 of the trailer 20. The leadingedge 48 can instead be secured at the back 54 of the trailer 20. Inorder to apply the underlayment layer 12 over the entire trucking cargo22, the roll 14 may then be moved towards the front 52 of the trailer20, over the free standing structure 16. Similarly, in the second andthird embodiments, the leading edge 48 may be secured proximate to theback 54 of the trailer 20 and the trucking cargo 22 may then be movedbackwards in the horizontal direction 34. While the embodiments of thepresent invention have been described, it is to be understood that theclaimed invention is not to be limited in scope to the aforementionedand described embodiments.

The invention claimed is:
 1. A method of applying a material layer totrucking cargo, comprising the steps of: providing a roll of materiallayer that is independent of the trucking cargo and a vehicle thattransports the trucking cargo, wherein the roll of material layer issupported by a frame that is separate from the trucking cargo; movingthe roll of material layer vertically with respect to the ground with avertical driving mechanism such that the roll of material layer iscapable of being moved closer to and farther from the ground to assistin covering the trucking cargo with the material layer in a verticaldirection of the trucking cargo; securing a leading edge of the materiallayer to the trucking cargo or vehicle; moving the roll of materiallayer in a horizontal plane parallel to the ground along a length of theframe and the trucking cargo in order to facilitate application of thematerial layer in a longitudinal direction of the trucking cargo with ahorizontal driving mechanism, wherein the horizontal driving mechanismis a rack and pinion assembly, thereby dispensing the material layerfrom the roll of material layer such that the material layer is appliedto the trucking cargo in the longitudinal direction of the truckingcargo so as to cover the trucking cargo; detaching the material layerfrom the roll of material layer; and securing a trailing edge of thematerial layer.
 2. The method of applying a material layer as set forthin claim 1, wherein the trucking cargo is carried by a trailer, andwherein the leading edge of the material layer is secured closer to thefront of the trailer than the trailing edge of the material layer. 3.The method of applying a material layer as set forth in claim 1, whereinthe step of moving the roll of material layer vertically with respect tothe ground is performed automatically with a vertical driving motor. 4.The method of applying a material layer as set forth in claim 1, whereinthe step of dispensing the material layer includes moving the truckingcargo forward while the roll of material layer remains stationary withrespect to the direction of travel of the trucking cargo.
 5. The methodof applying a material layer as set forth in claim 1, wherein the stepof dispensing the material layer includes moving the roll of materiallayer from the front of the trucking cargo to the back of the truckingcargo while the trucking cargo remains in a stationary position.
 6. Themethod of applying a material layer as set forth in claim 1, wherein thestep of detaching the material layer is accomplished through use of anelement selected from the group consisting of a utility knife,perforations defined in the material layer, and an automatic cuttingmechanism.
 7. A method of applying a material layer to trucking cargo,comprising the steps of: providing a roll of material layer that isindependent of the trucking cargo and a vehicle that transports thetrucking cargo, wherein the roll of material layer is supported by aframe that is separate from the trucking cargo; securing a leading edgeof the material layer to the trucking cargo or vehicle; moving the rollof material layer in a horizontal plane parallel to the ground along alength of the frame and the trucking cargo in order to facilitateapplication of the material layer in a longitudinal direction of thetrucking cargo with a horizontal driving mechanism, wherein thehorizontal driving mechanism is a rack and pinion assembly, therebydispensing the material layer from the roll of material layer such thatthe material layer is applied to the trucking cargo in the longitudinaldirection of the trucking cargo so as to cover the trucking cargo;detaching the material layer from the roll of material layer; andsecuring a trailing edge of the material layer.